Waterproof and uv-resistant form-fitting cover made of stretchable fabric

ABSTRACT

A waterproof and UV-resistant form-fitting cover comprising a four-way stretchable fabric that is pre-cut to an unstretched shape corresponding to 60-80% of a stretched shape that fits onto an object to be covered by the fabric, wherein the fabric is UV-resistant and waterproof. A method of manufacturing a form-fitting cover includes steps of receiving an electronic order specifying a size and shape for the cover, determining a material and blend based on the size and shape, computing a fabric size, and cutting a four-way stretchable fabric to an unstretched shape corresponding to the object to be covered.

TECHNICAL FIELD

The present invention relates generally to protective stretchable coversand, in particular, to protective covers made of a stretchable fabric.

BACKGROUND

Protective covers made of stretchable fabrics are known in the art.These covers are used to protect various objects from ultraviolet (UV)radiation from the sun, or from rain, snow, ice, wind, dust, or otherelements. Breathable fabrics are also used to reduce mildew.

Although covers made of stretchable fabric are known in the art, thereremains a need for an improved cover made of a stretchable fabric.

SUMMARY

The following presents a simplified summary of some embodiments of theinvention in order to provide a basic understanding of the invention.This summary is not an extensive overview of the invention. It is notintended to identify key/critical elements of the invention or todelineate the scope of the invention. Its sole purpose is to presentsome embodiments of the invention in a simplified form as a prelude tothe more detailed description that is presented later.

In general, a protective cover having a stretchable fabric is cut to asize and shape corresponding to an object to be cover such that theunstretched cover represents about 60-80% of the size of the object tobe covered.

Accordingly, an inventive aspect of the present disclosure is awaterproof and UV-resistant form-fitting cover comprising a four-waystretchable fabric that is pre-cut to an unstretched shape correspondingto 60-80% of a stretched shape that fits onto an object to be covered bythe fabric, wherein the fabric is UV-resistant and waterproof.

Another inventive aspect of the present disclosure is a method ofmanufacturing a form-fitting cover that includes steps of receiving anelectronic order specifying a size and shape for the cover, determininga material and blend based on the size and shape, computing a fabricsize, and cutting a four-way stretchable fabric to an unstretched shapecorresponding to the object to be covered.

Another inventive aspect of the present disclosure is a system formanufacturing a form-fitting cover. The system includes a communicationport for receiving an electronic order specifying a size and shape forthe cover, a processor for determining a material and blend based on thesize and shape and for computing a fabric size, and a fabric cuttercontrolled by the processor for cutting a four-way stretchable fabric toan unstretched shape corresponding to the object to be covered.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present technology will becomeapparent from the following detailed description, taken in combinationwith the appended drawings, in which:

FIG. 1 depicts a stretchable fabric for use in a protective cover inaccordance with an embodiment of the present invention;

FIG. 2 depicts an object to be covered;

FIG. 3 depicts the object covered by a protective cover in accordancewith an embodiment of the present invention;

FIG. 4 depicts, as an example, a boat covered by a protective cover;

FIG. 5 depicts, as an example, a wheel and tire covered by a protectivecover;

FIG. 6 depicts a system for manufacturing covers in accordance withanother embodiment of the present invention; and

FIG. 7 is a flowchart of a method of manufacturing covers.

It will be noted that throughout the appended drawings, like featuresare identified by like reference numerals.

DETAILED DESCRIPTION

In the following description, various embodiments of the presentinvention will be described. For purposes of explanation, specificconfigurations and details are set forth in order to provide a thoroughunderstanding of the embodiments. However, it will also be apparent toone skilled in the art that the present invention may be practicedwithout the specific details. Furthermore, well-known features may beomitted or simplified in order not to obscure the embodiment beingdescribed.

Disclosed herein are a stretchable cover, a method of manufacturing thestretchable cover and a system for manufacturing the stretchable cover.

Stretchable Cover

FIG. 1 depicts a fabric for use in a protective cover. The fabric isgenerally designated by reference numeral 10. The cover is made of astretchable fabric cut such that the shape of the unstretched fabric is60-80% of the shape of the object to be covered. In accordance with anembodiment of the present invention, a polyurethane film is laminatedonto the four-way stretch fabric to provide UV protection andwaterproofing.

The stretchable fabric may be a nylon/spandex fabric having a range ofblends. In one specific embodiment of this invention, the protectivefabric may be, for example, the Dri Tek 8020 from Eastex Products. Thisfabric is composed of 78% nylon and 22% spandex (elastane) laminated to1 mil polyurethane film with a thickness of 0.55 mm. Although aNylon/Spandex composition of 78% nylon/22% spandex provides excellentelasticity (“stretchability”), it will be appreciated that variations inthe composition may still provide excellent results. In one embodiment,the fabric is made of a 45 denier/13 filament dull nylon and a 40 denierspandex. It may optionally have a matte finish. In this embodiment, thefabric stretch is 80-100 weft/162-198 warp, although these stretchproperties may vary in other embodiments. It will be recalled that theweft is the term for the thread or yarn which is drawn through the warpyarns to create cloth. Warp is the lengthwise or longitudinal thread ina roll, while weft is the transverse thread. The fabric weight is 5.3oz/yd in this instance although this too may vary in other embodiments.The 1 mil polyurethane film may be made of an aromatic polyesterpolyurethane film/sheet having the following physical properties:durometer of 93-95 according to D2240 ASTM, a specific gravity of 1.2according to D792, a tensile-ultimate strength of L 10 000 according toD882, an elongation-ultimate strength of 650 according to D882, a tearstrength of 650 according to D1004. UV Resistance may tested under, ormade to comply with, any industry tests e.g. AATCC 16E outdoor colorfastness. Waterproofing may be tested as per AATCC 127.

In another embodiment, a blend of 82% nylon and 18% Lycra® spandex maybe employed. The Nylon may be a 6,6 Nylon (or 6-6 Nylon) which is apolymer made of hexamethylenediamine and adipic acid. The Lycra fibershave an ultimate extension of about 600%, thus providing excellentstretchability. This blend has a stretchability of approximately 200%lengthwise and 144% widthwise. In other embodiments, the fabric may be75/25 nylon/spandex, 70/30 nylon spandex, 65/35 nylon spandex or 60/40nylon/spandex. Different blends and different materials may be used fordifferent applications or uses. The fabric may be chemically treated orcoated to have other properties, e.g. fire-resistance, mold-resistance,etc.

Spandex, sometimes sold under the trade name LYCRA®, is a manufacturedfiber of a long-chain synthetic polymer containing at least 85 percentsegmented polyurethane. The polyurethane is prepared from a polyetherglycol, a mixture of diisocyanates, and a chain extender and thenmelt-spun, dry-spun or wet-spun to form the spandex fiber. Another typeof elastomeric yarn is polybutylene-terephtalate (PBT) yarn, a highlyelastic, friction-texturized polyester yarn available from Swicofil AGTextile Services of Emmenbruecke, Switzerland.

The fabric is UV-treated and waterproofed (e.g. by laminating a 1 milwaterproof polyurethane film) and then cut to specific dimensions to fitin a form-fitting manner over the object to the protected. For example,for a vehicle cover, the cover may be cut to approximate the shape ofthe vehicle, i.e. to approximately 70% of the length of the vehicle. Thefabric stretches the remaining 30% of the length to fit tautly over thevehicle. This provides a good fit that precludes the cover from beingblown off by the wind without stretching the material too much. Sincespandex fibers are prone to damage caused by various factors such asheat, light and chlorine, stabilizers such as antioxidants and lightstabilizers may be added to protect the fibers.

FIG. 2 shows an object 20 having an arbitrary shape. The object's shapemay have any geometry or may be composed of multiple joined or connectedshapes.

FIG. 3 shows a stretchable protective cover 30 fitted over the object.The fabric clings to the object by virtue of its elasticity. No couplingdevice is required. In other embodiments, though, a coupling device maybe used to further secure the cover to the object. The coupling devicemay be a hook and loop fastening system, a zipper, grommets, ropethrough loops, hooks through holes, magnets, straps, clips, belts,snaps, or any combination thereof.

FIG. 4 shows an example of a stretchable protective cover 40 for a boat.The waterproof fabric acts as a membrane to keep rain, snow, etc. fromentering the boat. The UV-resistance also protects the hull of the boat.

FIG. 5 shows an example of a stretchable protective cover 50 for a wheeland tire. In some embodiments, the cover may be printed to display alogo, advertisement or other graphics and/or text.

The covers may be pre-formed (pre-cut) to suit particular shapes ofobjects to be covered. Some examples of different covers include patiofurniture covers, boat covers, boat motor covers, snow machine(snowmobile) covers, motorcycle covers, 4 wheeler (quad) or ATV covers,BBQ covers, air conditioning covers, satellite covers, hot tub covers,car covers, tire covers, equipment covers, trailer covers, tonneaucovers, patio covers (over head), swing covers, transport truck covers,tank covers, hay covers, bicycle covers, road sign covers, lumber yardcovers, tree stand enclosures, tents, dust control barriers, miningunderground covers, trash covers, garden frost covers, wind breaks, etc.

The four-way stretchable waterproof and UV-resistant protective covermay be used for multiple objects. The cover also confers the followingbenefits or advantages: the cover is compact, very light weight,flexible, form-fitting, re-usable, breathable, user friendly, practical,inexpensive to manufacture, durable and washable. This fabric protectsobjects exposed to the elements from harmful effects of the sun (UVradiation), rain, snow, sleet, hail, wind, pollen, corrosive airbornesubstances, mildew, etc.

The product is also environmentally friendly since it reduces theamounts of disposable wraps and covers being put in the garbage. It alsohelps reduce water usage that would otherwise be needed to cleanunprotected objects.

System and Method of Manufacturing a Stretchable Cover

Another aspect of the present invention is a system and method ofmanufacturing a stretchable cover.

A novel computer-controlled method of manufacturing a stretchable coverinvolves electronically receiving an electronic customer order for acover (e.g. by e-mail or by website). The electronic order may formattedto be computer-readable. The order may include dimensions of an objectto be covered. The method may be implemented by a computer having aprocessor and memory and a communication port such as a modem orequivalent. The computer generates computer-aided manufacturing (CAM)commands and sends these commands to a cutting machine (e.g. a lasercutter) to cut the fabric to the desired dimensions. The order mayinclude uploading one or more photographs and key dimensions, e.g. sideand front view photos of a vehicle with the length and width of thevehicle from which the computer can calculate other visible dimensions,e.g. the height. The order may specify the object to be covered and/orthe intended usage of the cover. The computer can then determine thedesired material and/or the desired blend, and may also determine theamount of stretch to provide a desired form-fit on the object andwhether features such as waterproofing and UV resistant films are to beadded. The order may specify that the cover is to fit multiple similarlysized objects of different shape in which case the computer candetermine the optimal cover size, material and blend for the requestedmulti-use cover.

One example of a novel manufacturing system is illustrated in FIG. 6. Asshown by way of example in this figure, the system 100 receives anelectronic order sent from a user's networked computer 110 operated by auser or customer 120. The electronic order is communicated through theInternet 130 to the remote system 100. The system 100 has a computer (orserver) having a processor and memory and communication port (e.g.modem) for receiving the electronic order. The computer 140 may have anexternal database for storing material specifications, blendspecifications, inventory lists, prices, delivery times and costs, orother such information. The system 100 includes a fabric cutter 150,e.g. a laser cutter or other cutting apparatus. The cutter is controlledby commands or signals from the computer. The system 100 may alsoinclude a stitching machine 160 controlled by commands or signals fromthe computer. The electronic order may include digital photographs ofthe object to be covered. The user may take these photos using a digitalcamera 112 and upload these to the computer 110 by wired or wirelessconnection. The electronic order may include dimensions of the object tobe covered, e.g. length (L), width (W) and height (H). The system 100may also include a billing module and/or a packaging machine.

The novel method is summarized in general terms in the flowchart of FIG.7. As depicted in this flowchart, the method include an initial step 200of receiving an electronic order specifying a size and shape for thecover. The method then includes a subsequent step 210 of determining amaterial and blend based on the size and shape and a step 220 ofcomputing a fabric size. The method then involves a further step 230 ofcutting a four-way stretchable fabric to an unstretched shapecorresponding to the object to be covered. The fabric may then bestitched as part of the finishing of the stretchable cover.

This method and system enables a stretchable fabric cover to be easilyordered online by a customer. The system can automatically manufacturethe cover based on the information contained in the electronic order.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. The term “connected” is to beconstrued as partly or wholly contained within, attached to, or joinedtogether, even if there is something intervening. Recitation of rangesof values herein are merely intended to serve as a shorthand method ofreferring individually to each separate value falling within the range,unless otherwise indicated herein, and each separate value isincorporated into the specification as if it were individually recitedherein. All methods described herein can be performed in any suitableorder unless otherwise indicated herein or otherwise clearlycontradicted by context. The use of any and all examples, or exemplarylanguage (e.g., “such as”) provided herein, is intended merely to betterilluminate embodiments of the invention and does not pose a limitationon the scope of the invention unless otherwise claimed. No language inthe specification should be construed as indicating any non-claimedelement as essential to the practice of the invention.

The embodiments of the invention described above are intended to beexemplary only. As will be appreciated by those of ordinary skill in theart, to whom this specification is addressed, many obvious variations,modifications, and refinements can be made to the embodiments presentedherein without departing from the inventive concept(s) disclosed herein.The scope of the exclusive right sought by the applicant(s) is thereforeintended to be limited solely by the appended claims.

1. A waterproof and UV-resistant form-fitting cover comprising: afour-way stretchable fabric that is pre-cut to an unstretched shapecorresponding to 60-80% of a stretched shape that fits onto an object tobe covered by the fabric; wherein the fabric is UV-resistant. whereinthe fabric is waterproof.
 2. The cover of claim 1 wherein the fabric is80% nylon and 20% spandex.
 3. The cover of claim 1 wherein theunstretched shape corresponds 70% to the shape of the object to becovered.
 4. A method of manufacturing a form-fitting cover, the methodcomprising: receiving an electronic order specifying a size and shapefor the cover; determining a material and blend based on the size andshape; computing a fabric size; and cutting a four-way stretchablefabric to an unstretched shape corresponding to the object to becovered.
 5. The method of claim 4 wherein the fabric is 80% nylon and20% spandex.
 6. The method of claim 5 further comprising coating thefabric with a UV-resistant film.
 7. The method of claim 5 furthercomprising coating the fabric with a waterproof film.
 8. A system formanufacturing a form-fitting cover, the system comprising: acommunication port for receiving an electronic order specifying a sizeand shape for the cover; a processor for determining a material andblend based on the size and shape and for computing a fabric size; and afabric cutter controlled by the processor for cutting a four-waystretchable fabric to an unstretched shape corresponding to the objectto be covered.
 9. The system of claim 8 wherein the fabric is 80% nylonand 20% spandex.
 10. The system of claim 9 further comprising a coatingmachine for coating the fabric with a UV-resistant film.
 11. The systemof claim 9 further comprising a coating machine for coating the fabricwith a waterproof film.